Cannondale E440 2003 User manual

2003 Motorcycle Owner’s Manual
Models : E440, C440, X440, S440
P/N : 951-5002274-03
Before you operate the vehicle. . . .
• READ and UNDERSTAND this Owner’s Manual.
It contains information important to your safety.
• Learn the location and proper operation of all controls.
• Complete the Pre-Ride Inspection checklist.
• Wear appropriate protective gear - approved full faced helmet, eye
protection, gloves, boots, long-sleeve shirt, and pants.
Consider purchasing specially designed protective off-road vehicle
riding apparel.

© 2002 Cannondale Corporation - All Rights Reserved
2003 Motorcycle OM Cover.fm
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY
OR DEATH.
Information important to your safety is distinguished in this manual by the following notations: \
The safety alert symbol means......
“ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED.”
Indicates that DEATH or severe injury WILL result if the
instructions are not followed.
Indicates a potential hazard that could result in serious
injury or death.
A CAUTION indicates that special precautions must be
taken to avoid damage to the machine.
A NOTE provides helpful information intended to make
maintenance easier or the instructions presented clearer.
DANGER
WARNING
CAUTION:
NOTE:

3
Printed : 8/15/02
3
CONTENTS
IMPORTANT MANUAL INFORMATION- - - - - - - - - - - 2
FOREWORD - - - - - - - - - - - - - - - - - - - - - - - - 4
General Safety Precautions - - - - - - - - - - - - 5
Experienced riders only - - - - - - - - - - - - - - 7
Exercise good judgement- - - - - - - - - - - - - - 7
No Modifications - - - - - - - - - - - - - - - - - - 7
No passengers- - - - - - - - - - - - - - - - - - - 7
Inspection of Aluminum chassis components - - - - 8
VEHICLE WARNING AND SPECIFICATION LABELS - - 10
VEHICLE IDENTIFICATION- - - - - - - - - - - - - - - - 12
Vehicle Identification Number (VIN)- - - - - - - - 12
Engine Serial Number - - - - - - - - - - - - - - 12
PARTS AND CONTROLS- - - - - - - - - - - - - - - - - 13
Engine start button - - - - - - - - - - - - - - - - 13
Engine ON/OFF Switch- - - - - - - - - - - - - - 14
Headlight and Taillight (USA) - - - - - - - - - - 14
lighting Option - - - - - - - - - - - - - - - - - - 15
Trip computer - - - - - - - - - - - - - - - - - - 15
Clutch lever - - - - - - - - - - - - - - - - - - - 16
Shift lever - - - - - - - - - - - - - - - - - - - - 16
Throttle Grip - - - - - - - - - - - - - - - - - - 16
Front brake lever - - - - - - - - - - - - - - - - - 18
Footpegs- - - - - - - - - - - - - - - - - - - - - 19
Rear brake pedal- - - - - - - - - - - - - - - - - 20
Side stand (or) kickstand- - - - - - - - - - - - - 21
Handguards - - - - - - - - - - - - - - - - - - - 23
Fuel tank cap - - - - - - - - - - - - - - - - - - 24
FLUIDS- - - - - - - - - - - - - - - - - - - - - - - - - - 24
Brake fluid - - - - - - - - - - - - - - - - - - - - 24
Coolant - - - - - - - - - - - - - - - - - - - - - 26
Engine oil - - - - - - - - - - - - - - - - - - - - 28
Hydraulic clutch fluid - - - - - - - - - - - - - - - 32
Fuel - - - - - - - - - - - - - - - - - - - - - - - 35
Transmission oil - - - - - - - - - - - - - - - - - 38
PRE-RIDE INSPECTION - - - - - - - - - - - - - - - - - 40
OPERATION - - - - - - - - - - - - - - - - - - - - - - - 42
Starting a warm engine- - - - - - - - - - - - - - 42
Jump starting - - - - - - - - - - - - - - - - - - 42
Shifting gears - - - - - - - - - - - - - - - - - - 43
Braking - - - - - - - - - - - - - - - - - - - - - 44
Post ride checks - - - - - - - - - - - - - - - - - 44
BREAK-IN - - - - - - - - - - - - - - - - - - - - - - - - 45
MAINTENANCE & ADJUSTMENT - - - - - - - - - - - - 46
Maintenance schedule - - - - - - - - - - - - - - 47
Seat - - - - - - - - - - - - - - - - - - - - - - - 49
Air filter- - - - - - - - - - - - - - - - - - - - - - 51
Brakes - - - - - - - - - - - - - - - - - - - - - - 53
Clutch - - - - - - - - - - - - - - - - - - - - - - 54
Drive - - - - - - - - - - - - - - - - - - - - - - - 54
Engine Management System - - - - - - - - - - - 61
Electrical - - - - - - - - - - - - - - - - - - - - - 62
Exhaust - - - - - - - - - - - - - - - - - - - - - 68
Fuel - - - - - - - - - - - - - - - - - - - - - - - 70
Steering - - - - - - - - - - - - - - - - - - - - - 73
Suspension- - - - - - - - - - - - - - - - - - - - 75
Adjustment - - - - - - - - - - - - - - - - - - - - 75
Tires - - - - - - - - - - - - - - - - - - - - - - - 87
Wheels- - - - - - - - - - - - - - - - - - - - - - 88
CLEANING - - - - - - - - - - - - - - - - - - - - - - - - 93
STORAGE - - - - - - - - - - - - - - - - - - - - - - - - 94
TIGHTENING TORQUES - - - - - - - - - - - - - - - - - 96
MAINTENANCE RECORD - - - - - - - - - - - - - - - - 97
SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - 98
Service - - - - - - - - - - - - - - - - - - - - - 99
Suspension Settings - - - - - - - - - - - - - - 100
ADDENDA - - - - - - - - - - - - - - - - - - - - - - - -101
WARNING Indicates a potential hazard
that could result in serious
injury or death.
When reading this manual, remember:

© 2002 Cannondale Corporation - All Rights Reserved
4
2003 Motorcycle OM.fm
WARNING Indicates a potential hazard that could result in serious injury or death.
FOREWORD
This Owner’s Manual has been written carefully to provide you with a good basic understanding of all the features,
controls, proper operation, and maintenance of your vehicle. It also will provide you with important safety
information for you and anyone who operates it.
This manual should be considered a permanent part of the vehicle and it should remain with the vehicle whenever
it is resold or possession is transferred to another person. Please take the time necessary to read and understand
this entire owner’s manual.
Limitations
All information, illustrations, and specifications in this manual are based on the latest product information available
at the time of publication. Cannondale Corporation reserves the right to make changes at any time, without notice.
This vehicle has U.S. and International patents pending.
Comments
Send your comments or suggestions about this manual to: Technical Publications, Cannondale Corporation, 2 Cor-
porate Drive, Bedford, PA, 15522. Or, E-mail us at: [e-mail].
IMPORTANT NOTICE
Some information in this manual may be outdated due to ongoing model improvements made
after the date of publication. The Addenda section at the end of this manual includes any addi-
tional, replacement, or supplemental information for your vehicle that is available at the time of
shipment.
You can download a Adobe PDF copy of this Owner’s Manual as well as any applicable
addenda, free of charge from our website. Go to: http://www.cannondale.com/motorsports/tech/
manuals.html,
Anytime you have any question related to the controls, features, or operation and maintenance of
your vehicle, please consult your Cannondale dealer. Or, call us at toll free at 1-800-MOTO-USA.

5
Printed : 8/15/02
5
GENERAL SAFETY PRECAUTIONS
DANGER
POTENTIAL HAZARD
Running the engine indoors
Breathing exhaust gases
WHAT CAN HAPPEN
Running the engine indoors will expose you
to dangerous exhaust gases. Breathing car-
bon monoxide gas leads to poisoning,
asphyxiation, and death. This will happen
rapidly and without notice.
HOW TO AVOID THE HAZARD
Never operate the vehicle indoors even for
brief periods of time.
WARNING
POTENTIAL HAZARD
Improper care when handling fuel
WHAT CAN HAPPEN
Fuel is highly flammable; spilling it can
cause a fire or explosion.
HOW TO AVOID THE HAZARD
Be sure the fuel cap is closed securely.
Work in a well-ventilated area which is free of
sources that could ignite any spilled fuel
accidentally (e.g. cigarettes, welders,
torches, grinders, electric shop tools, etc.)